Illumination system

ABSTRACT

An illumination system has a mounting plate, a plurality of thermally conductive circuit boards in thermal contact with the mounting plate, a plurality of light emitting diodes electrically and thermally communicating with the circuit board strips, an optical lens formed as a translucent dome covering the circuit boards and light emitting diodes, and a lamp base operatively coupled to the mounting plate and circuit boards. The light emitting diodes receive power from an external electrical source entering the system through the base and the circuit boards.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an illumination system and moreparticularly pertains to providing efficient and highly recognizabledevices for producing light.

2. Description of the Prior Art

The use of illumination systems of known designs and configurations isknown in the prior art. More specifically, illumination systems of knowndesigns and configurations previously devised and utilized for thepurpose of providing recognizable devices for producing light are knownto consist basically of familiar, expected, and obvious structuralconfigurations, notwithstanding the myriad of designs encompassed by thecrowded prior art which has been developed for the fulfillment ofcountless objectives and requirements.

By way of example, U.S. Pat. No. 6,425,678 issued Jul. 30, 2002 toVerdes.

While the prior art devices fulfill their respective, particularobjectives and requirements, they do not describe illumination systemthat provides efficient and highly recognizable devices for producinglight.

In this respect, the illumination system according to the presentinvention substantially departs from the conventional concepts anddesigns of the prior art, and in doing so provides an apparatusprimarily developed for the purpose of providing efficient and highlyrecognizable devices for producing light.

Therefore, it can be appreciated that there exists a continuing need fora new and improved illumination system which can be used for providingefficient and highly recognizable devices for producing light. In thisregard, the present invention substantially fulfills this need.

SUMMARY OF THE INVENTION

In view of the foregoing disadvantages inherent in the known types ofillumination systems of known designs and configurations now present inthe prior art, the present invention provides an improved illuminationsystem. As such, the general purpose of the present invention, whichwill be described subsequently in greater detail, is to provide a newand improved illumination system and method which has all the advantagesof the prior art and none of the disadvantages.

To attain this, the present invention essentially comprises a thincircular plate comprised of thermally conductive material. The circularplate has an upper surface and a lower surface with a plurality ofradially paired apertures extending there through and located equallyspaced there around. The circular plate has an external diameter of afirst diameter size.

Next provided are a plurality of rectilinear “L” shaped thermallyconductive circuit boards. Each circuit board has an internal face, anexternal face, a pair of parallel side edges. Each circuit board alsohas a long vertical portion and a short horizontal portion and a bendbetween the long vertical portion and the short vertical portion. A pairof apertures is provided through the short horizontal portion. Thecircuit boards are arranged in a circular configuration with adjacentparallel side edges being located adjacent each other and all theinternal faces forming a hexagonal circular configuration and coupled tothe plate such that the pair of apertures of the plate are aligned withthe paired apertures of the short horizontal portion of the circuitboards.

A plurality of light emitting diodes function as light emitters. Thediodes are coupled to the long vertical portion of the circuit boardwith thermally conductive paste adapted to maximize heat transfer. Thediodes are electrically coupled to a circuit provided thereon.

Next, an optical lens of a generally cylindrical configuration formed asa translucent dome is enclosed. The lens has a closed top end and anopen bottom end having an internal step having an internal diameterhaving a second diameter size, the second diameter being larger than thefirst diameter. The optical lens is comprised of a transparent material.The lens has a beam pattern as required for the specific application.The open bottom end is configured to receive and hold the circularplate. The open bottom end of the lens has a lip having a third externaldiameter, the third diameter being larger than the second diameter.

A mounting base is next provided. The mounting base is of a generallycylindrical configuration with an open top part, a closed bottom partand a side face there around. The top part has a lip adapted to lieadjacent the lower surface of the plate and within the lens. The lip hasan external diameter having the size of a first diameter, so that thelip is received within the second internal diameter of the lens. The lipof the base also has a third external diameter sized to match and matewith the external third diameter of the lens. The base has a socketaperture and flange extending from the mounting base. The base has awire aperture there through to allow the passage of wires.

A plurality of rivets are provided. The rivets couple the circuit boardsand the plate together.

A gasket is provided to be positioned between the lower lip and theupper lens. The gasket provides a weather-proof seal against theelements.

Lastly, a retainer ring is provided. The retainer ring has a thirdinternal diameter and is configured to couple together the lens and theplate and the mounting base.

The light emitting diodes are adapted to receive power from an externalelectrical source configured to enter the system through the wiringaperture of the mounting base through the circuit board to the lightemitting diode. The electrical source may be either alternating currentor direct current, preferably direct current. The system is configuredto work within current ranges of between about 300 mille-Amperes and 5Amperes. The diodes are arranged in pairs, with each pair being wired inparallel so that with the failure of one diode of a pair, the currentcan be readily handled by the other diode of the pair. A plurality ofpairs of diodes, or working sets, are arranged in series.

There has thus been outlined, rather broadly, the more importantfeatures of the invention in order that the detailed description thereofthat follows may be better understood and in order that the presentcontribution to the art may be better appreciated. There are, of course,additional features of the invention that will be described hereinafterand which will form the subject matter of the claims attached.

In this respect, before explaining at least one embodiment of theinvention in detail, it is to be understood that the invention is notlimited in its application to the details of construction and to thearrangements of the components set forth in the following description orillustrated in the drawings. The invention is capable of otherembodiments and of being practiced and carried out in various ways.Also, it is to be understood that the phraseology and terminologyemployed herein are for the purpose of descriptions and should not beregarded as limiting.

As such, those skilled in the art will appreciate that the conception,upon which this disclosure is based, may readily be utilized as a basisfor the designing of other structures, methods and systems for carryingout the several purposes of the present invention. It is important,therefore, that the claims be regarded as including such equivalentconstructions insofar as they do not depart from the spirit and scope ofthe present invention.

It is therefore an object of the present invention to provide a new andimproved illumination system which has all of the advantages of theprior art illumination systems of known designs and configurations andnone of the disadvantages.

It is another object of the present invention to provide a new andimproved illumination system which may be easily and efficientlymanufactured and marketed.

It is further object of the present invention to provide a new andimproved illumination system which is of durable and reliableconstructions.

An even further object of the present invention is to provide a new andimproved illumination system which is susceptible of a low cost ofmanufacture with regard to both materials and labor, and whichaccordingly is then susceptible of low prices of sale to the consumingpublic, thereby making such illumination system economically available.

Even still another object of the present invention is to provide anillumination system for providing efficient and highly recognizabledevices for producing light.

Lastly, it is an object of the present invention to provide a new andimproved illumination system with a mounting plate, a plurality ofthermally conductive circuit boards in thermal contact with the mountingplate, a plurality of light emitting diodes electrically and thermallycommunicating with the circuit board strips, an optical lens formed as atranslucent dome covering the circuit boards and light emitting diodes,and a lamp base operatively coupled to the mounting plate and circuitboards. The light emitting diodes receive power from an externalelectrical source entering the system through the base and the circuitboards. Circuitry can give the status of the system at any given time.

These together with other objects of the invention, along with thevarious features of novelty which characterize the invention, arepointed out with particularity in the claims annexed to and forming apart of this disclosure. For a better understanding of the invention,its operating advantages and the specific objects attained by its uses,reference should be had to the accompanying drawings and descriptivematter in which there is illustrated preferred embodiments of theinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood and objects other than those setforth above will become apparent when consideration is given to thefollowing detailed description thereof. Such description makes referenceto the annexed drawings wherein:

FIG. 1 is a perspective illustration of an LED obstruction lightingsystem constructed in accordance with the principles of the presentinvention.

FIG. 2 is a perspective illustration of the circular plate demonstratingthe relationship of the paired apertures.

FIG. 2A is a perspective illustration of the circular plate not having acentral aperture.

FIG. 3 is a perspective illustration of one of the circuit boards with alight emitting diode coupled thereto.

FIG. 4 is a perspective illustration of the system shown in FIG. 2 butwith the base removed.

FIG. 5 is a perspective illustration of an alternate embodiment of thebase.

FIG. 6 is a perspective of the circular plate with the “L” shapedthermally conductive circuit boards, with Led's, coupled thereto.

FIG. 7 is a side perspective of an alternate embodiment of theIllumination System.

The same reference numerals refer to the same parts throughout thevarious Figures.

DESCRIPTION OF THE PREFERRED EMBODIMENT

With reference now to the drawings, and in particular to FIG. 1 thereof,the preferred embodiment of the new and improved illumination systemembodying the principles and concepts of the present invention andgenerally designated by the reference numeral 10 will be described.

The present invention, the illumination system 10 is comprised of aplurality of components. Such components in their broadest contextinclude a circular mounting plate, a plurality of thermally conductivecircuit boards, a plurality of light emitting diodes, an optical lensformed and a lamp base. Such components are individually configured andcorrelated with respect to each other so as to attain the desiredobjective.

The present invention essentially comprises a thin circular plate 12comprised of thermally conductive material. The circular plate has anupper surface 14 and a lower surface 16 with a plurality of radiallypaired apertures 18 extending there through and located equally spacedthere around. The circular plate has an external diameter of a firstdiameter size. The circular plate may have a central aperture, or theplate may be configured without having a central aperture.

Next provided are a plurality of rectilinear “L” shaped thermallyconductive circuit boards 20. Each circuit board has an internal face22, an external face 24, a pair of parallel side edges 26, 28. Eachcircuit board also has a long vertical portion 30 and a short horizontalportion 32 and a bend 34 between the long vertical portion and the shortvertical portion. A pair of apertures 36, 38 is provided through theshort horizontal portion.

The circuit boards are arranged in a circular configuration withadjacent parallel side edges being located adjacent each other and allthe internal faces forming a symmetrical configuration and coupled tothe plate such that the pair of apertures of the plate are aligned withthe paired apertures of the short horizontal portion of the circuitboards.

A plurality of light emitting diodes 37, 39 function as light emitters.The diodes are coupled to the external face of the long vertical portionof the circuit board with thermally conductive paste adapted to maximizeheat transfer. The diodes are electrically coupled to a circuit providedthereon. A single diode may be coupled to a circuit board, or more thanone diode may be coupled to the circuit board, depending on the desiredresult.

Next, an optical lens 40 of a generally cylindrical configuration formedas a translucent, clear or colored dome is enclosed. The lens has aclosed top end 42 and an open bottom end 44 having an internal stephaving an internal diameter having a second diameter size, the seconddiameter being larger than the first diameter. The optical lens iscomprised of a transparent material. The lens has a Fresnel-type beampattern as required for specific applications. The open bottom end isconfigured to receive and hold the circular plate. The open bottom endof the lens has a lip 49 having a third external diameter, the thirddiameter being larger than the second diameter.

A mounting base 50 is next provided. The mounting base is of a generallycylindrical configuration with an open top part 52, a closed bottom part54 and a side face 56 there around. The top part has a lip 58 adapted tolie adjacent the lower surface of the plate and within the lens. The liphas an external diameter having the size of a first diameter, so thatthe lip is received within the second internal diameter of the lens. Thelip of the base also has a third external diameter sized to match andmate with the external third diameter of the lens.

The base has a entrance aperture 59 to allow the passage of wires, and aflange extending from the mounting base.

A plurality of rivets 60 are provided. The rivets couple the circuitboards and the plate together.

Lastly a retainer ring 70 is provided. The retainer ring has a thirdinternal diameter and is configured to couple together the lens and theplate and the mounting base.

In an alternate embodiment, the system may be coupled together by ameans other than a retainer ring. The lens and base may be threadedlycoupled, or may be coupled by a snap means.

The light emitting diodes are adapted to receive power from an externalelectrical source configured to enter the system through the entranceaperture of the mounting base through the circuit board to the lightemitting diode. The electrical source may be either alternating currentor direct current, preferably direct current. The system is configuredto work within current ranges of between about 300 mille-Amperes and 5Amperes.

The diodes are arranged in pairs, with each pair being wired in parallelso that with the failure of one diode of a pair, the current can bereadily handled by the other diode of the pair. A plurality of pairs ofdiodes, or working sets, are arranged in series.

In a working model, Luxeon brand red emitters operating at 350Mille-Amperes with an acrylic Fresnel dome lens meet or exceed therequirements for obstruction lights when the emitters are affixed tofour or more boards and positioned in a horizontal circular arrangementhaving a minimal diameter.

The parallel combination of LED's are driven using a constant currentpower source as typically used in powering LEDs. The current applied isset to the operating current of a single LED. Powering LEDs from thissource results in current sharing between LEDs and approximately half ofthe current will be applied to each LED. Operation at half current willresult in a greatly increased LED lifetime. Additionally, should one LEDfail (open circuit) on a given circuit board, the remaining LED will bepowered at full current and the lumenaire will continue to operate atfull optional output, thereby increasing lifetime. Note that thevertical separation of LEDs should be minimal as the peak optical outputof the lumenaire will shift position upward or downward depending onwhich LED fails. Tests have shown that the vertical displacement doesnot invalidate use of this invention in aircraft obstruction and taxiwaylighting.

Emitter are affixed to thermal conductive circuit boards in a mannerthat facilitates heat conduction from emitter to board. This mode ofheat transfer forms the novelty of this invention since prior art uses amore costly, less efficient, cylindrical heat sink to remove heat fromthe emitters. In practice, the emitter has a large scale surface mountcomponent that is soldered to electrically conductive traces on theboard. Thermal contact is ensured by the use of thermally conductivepaste which is applied between the emitter and the board. In addition,the solder tabs of each emitter removes heat from the emitter andconveys this heat to solder pads on the circuit board. Heat generated byemitter must be removed to the environment to preclude failure orreduced light output.

Heat collected by the circuit board is transported to the environmentthrough convective and conductive means. Convective heat loss isrealized by heating the air confined within the lens, which circulatesexchanging heat with the plastic or the glass lens. The lens dissipatesheat to the environment primarily by convection. Conductive heat loss isrealized by thermally conductive path through the length of the circuitboard.

Thermally conductive paste is applied at the interface of the boards andthe plate to maximize heat transfer. The circular plate is fabricated ofa thermally conductive composition and may comprise an aluminum disk ora circular J-P Clad thermally conductive circuit board having electricalcircuit components mounted thereto. Heat reaching the plate istransferred to the base and the ring by maintaining good thermalcontact. The base and ring heat is dissipated to the environment throughconvective process and mounting arrangements.

In the preferred embodiment the lens will be sealed to the plate and anyholes, fasteners, and electrical interfaces will also be sealed therebyproviding an environmentally isolated portion. This sealed portion willbe less susceptible to installation damage, be immune to corrosiveatmospheres, and enable pre-focusing of the emitter/lens combinationthereby providing superior product quality.

Emitters produce light in a diverging beam that is collected by the lensand formed into a beam pattern as required for an application. As anaircraft obstruction light, the output beam is a red color, covers 360degrees azimuthally, and produces at least 32.5 candela over a 10-degreeband centered between 4 and 20 degrees above a horizontal plane.

In another alternate embodiment, one or more additional emitters ispositioned to produce light traveling in a vertical direction. Thislight emission will satisfy the aviation requirements for Canada (CSA.)These emitters may be affixed to the ends of board or one or more boardsmay be extended and bent at 90 degrees to accommodate mounting anemitter having a vertical light output disposition.

And yet another alternate embodiment employs more than one emitter oneach circuit board. This embodiment includes that previously described.

As to the manner of usage and operation of the present invention, thesame should be apparent from the above description. Accordingly, nofurther discussion relating to the manner of usage and operation will beprovided.

With respect to the above description then, it is to be realized thatthe optimum dimensional relationships for the parts of the invention, toinclude variations in size, materials, shape, form, function and mannerof operation, assembly and use, are deemed readily apparent and obviousto one skilled in the art, and all equivalent relationships to thoseillustrated in the drawings and described in the specification areintended to be encompassed by the present invention.

Therefore, the foregoing is considered as illustrative only of theprinciples of the invention. Further, since numerous modifications andchanges will readily occur to those skilled in the art, it is notdesired to limit the invention to the exact construction and operationshown and described, and accordingly, all suitable modifications andequivalents may be resorted to, falling within the scope of theinvention.

1. An illumination system for providing efficient and highlyrecognizable devices for producing light comprising in combination: athin circular plate comprised of thermally conductive material having anupper surface and a lower surface; a plurality of rectilinear “L” shapedthermally conductive circuit boards each having an internal face, anexternal face, a pair of parallel side edges, a vertical portion and ahorizontal portion and a bend there between, with the external face ofthe vertical portion having a means for attachment of at least one LED,and the horizontal portion having a means for attachment to the plate,the circuit boards being arranged in a configuration with adjacentparallel side edges separated from each other; at least one lightemitting diode functioning as a light emitter being coupled to thevertical portion of the circuit board with means to maximize heattransfer; an optical lens of a generally cylindrical configurationformed as a dome having a closed top end and an open bottom end andcomprised of a transparent material, the open bottom end beingconfigured to lie adjacent to the upper surface of the plate; a mountingbase of a generally cylindrical configuration with an open top part, aclosed bottom part and a side face there around, the top part having alip adapted to lie adjacent the lower surface of the plate with anaperture and flange extending from the mounting base; a plurality ofrivets adapted to couple together the circuit boards and the plate andthe base; a retainer ring adapted to couple together the lens and theplate and the mounting base; and an external electrical sourceoperatively coupled to the system.